GTI Gasification and Gas GTI Gasification and Gas Processing R&D ProgramProcessing R&D Program

ASERTTI 2007

2

> Research, deployment and training for the Natural Gas Industry and energy markets

> 65 years, 1000+ patents, 500 products> 18 acre campus, 200,000 ft2 of lab and

office space> 50 years of Gasification R&D

1700 S. Mount Prospect Road. Des Plaines, IL 60018

3

GoalsGoals

> Increase the use of coal and biomass through the development, evaluation and commercialization of new gasification technologies.

> Develop and evaluate new technologies to clean/treat syngas for various end use applications.

> Integrate advanced gasification-based technologies with end-use technologies for production of power, fuels, and chemicals.

Increasing Energy Supply with Advanced Processes to Convert Coal and Biomass to Power, Fuels, and

Chemicals.

4

Gasification and Gas Process R&D Gasification and Gas Process R&D ExpertiseExpertise

> Advanced gasification systems

> Gas cleanup systems for sour gas and syngas

> Integration of syngas production and conversion

> Process simulation and techno-economic evaluations

5

HYGAS-SNG

STEAM-IRON-H2

U-GAS-Syngas

RENUGAS-SyngasMild-GAS-Coal-refining

GTI Energy Development CenterGTI Energy Development Center

Leader of International Energy Agency (IEA) Task 33 -Biomass Gasification since the Task inception in 1989.

19511951--19961996

6

ScaleScale--up and Investment History of GTI up and Investment History of GTI Gasification TechnologyGasification Technology

Capa

city

, To

ns/d

ay

1

10

100

1000

1970 1975 1980 1985 1990 1995 2000 2005

24

80

30

100

150

40

HP Biomass

HP Coal

LP Coal

10

Total Investments

US$ M

illions

8

40

20

Flex-FuelShanghaiMaui

FinlandRENUGASChicago

UGAS Pilot and PDU - Chicago

2010

165

Skive, DenmarkHai Hua, China

400

0

50

100

150

200

250

7

100 ton per day Bioenergy Demo Plant in Hawaii using bagasse

1000 ton per day U-GAS® Industrial fuel gas in Shanghai, China using coal

80 ton per day Gasification Pilot Plant in Tampere, Finland using biomass & coal

Gasifier ProjectsGasifier Projects

165 ton per day CHP Plant in Skive, Denmark using wood

8

GTIGTI’’ss FlexFlex--Fuel Test Facility:Fuel Test Facility:A Technology Development and A Technology Development and

Systems Integration PlatformSystems Integration Platform

> Flexible fuel capability

> Operational flexibility

> Plug and play systems integration and testing

9

Features• Coal – 10 tpd w/air; 20 tpd w/oxygen

• Biomass – 24 tpd w/air; 40 tpd w/oxygen

• Gasification Pressure to 28 atm

• Multi-contaminant Syngas Cleanup

• On-line Syngas Analysis Systems

Process Evaluations• Hydrogen Production

• SNG Production

• CO2 Capture Technologies

• Syngas-to-Liquids Production

• Advanced Power Conversion Systems

• Advanced Oxygen Production Systems

• Industrial Syngas End-Use

Commercial Operator Training

FlexFlex--Fuel Test Facility OverviewFuel Test Facility Overview

Industrial Combustion Lab

10

Gas

ifica

tion

Sys

tem

s

GTI Projects Relevance to FutureGenGTI Projects Relevance to FutureGen

•Siemens Novel Gas Cleaning•UCSRP-HP Multicontaminant

•Catalytic gasification for SNG•Fluidized bed gasifier•Advanced Compact Gasifier

•Morphysorb•Membranes

•Fischer-Tropsch Liquids•Hydrogen Membranes

Coal-Based Hybrid Solid Oxide Fuel Cell

11

Objectives of Selected Gasification and Gas Objectives of Selected Gasification and Gas Processing ProjectsProcessing Projects

GASIFICATION> bluegas® Catalytic Gasification (GreatPoint Energy): Produce low-cost

substitute natural gas (SNG) from coal via catalytic gasification.

> Advanced Compact Gasifier (Pratt & Whitney Rocketdyne, GTI, DOE):Convert all ranks of coal to power and fuels at high efficiency and economy with an advanced entrained gasifier.*

> IGCC for India (USAID, Nexant): Support design of U-GAS® solution for advanced power production in India.

SYNGAS PROCESSING> Novel Gas Cleaning Process (Siemens Power Generation, DOE): Remove

hot syngas contaminants to ultra-clean levels for high-efficiency IGCC (fuel cell) and chemicals applications.*

> UCSRP-HP Multi-contaminant Process (DOE, ICCI): Develop a new, inexpensive process to remove and recover multiple contaminants in coal-derived syngas.*

* Projects with DOE participation

12

Objectives of Selected Gasification and Objectives of Selected Gasification and Gas Processing Projects (2)Gas Processing Projects (2)SYNGAS PROCESSING (cont’d)> Acid Gas Treatment Pilot Plant (IL DCEO, GTI): Efficiently capture

sulfur and CO2 from syngas for acid gas and carbon management.

> Engineered Catalyst for In-Situ Elimination of Tar (DOE-EERE, GTI):Create a lower-cost, high-performing catalyst for tar reductions in biomass gasifiers.

> Hydrogen Production from Biomass Gasification (Xcel): Demonstrate membranes for H2 separation from biomass-derived syngas.

SYNGAS CONVERSION> Coal-Derived High-Hydrogen Content Fischer-Tropsch Liquids

(Headwaters, GTI, DOE): Produce Fischer-Tropsch liquids from coal using iron-based catalysts.*

> Coal-Based Hybrid Solid Oxide Fuel Cell (FuelCell Energy, Versa Power, DOE): Prove feasibility of SOFC for high-efficiency power in the FutureGen concept.*

* Projects with DOE participation

13

Acid Gas Treatment Pilot PlantAcid Gas Treatment Pilot PlantValue: Sulfur and CO2 capture for low

emissions and carbon management

> Sponsor: State of Illinois DCEO, GTI

> Scope– Refurbish and Reconfigure the Acid Gas

Treatment Pilot Plant for syngas application

– Integrate with FFTF for sulfur and CO2

removal evaluation on syngas

> Status

– Equipment installed at FFTF in 2006

14

UltraUltra--Clean Syngas ProcessClean Syngas Process

Sorbent Fines

Ultra-Clean Syngas

SyngasCooler

Sulfur & Halide Bulk Removal

System

SorbentsMakeup and

Disposal

SorbentFines

Injection

SorbentFines

Injection

RawSyngas

Sorbent Fines& Char

RecoveredSulfur Stage I

Filter -ReactorStage II

Filter -ReactorGasifier

Cyclone

RawFuel Gas

Bedchar/sorbent

Cyclonechar/sorbent

Steam

Oxidant

Coal, Biomass, OtherCarbonaceous Fuels

Limestonesorbent

Particulate < 0.1 ppmwTotal S (H2S, COS) ~ 1 to 5 ppmvHalide (HCl) ~ 1 to 5 ppmv

Particulate < 0.1 ppmwTotal S (H2S, COS) ~ 20 ppbvHalide (HCl) ~ 10 ppbvHg ~ 50 to 70% removal (at 570ºF)

H2S : 35 ppmv (9.3 lb/hr)HCl : 250 ppmv (74 lb/hr)Part. : 10,000 ppmw (1600 lb/hr)

Value: Syngas contaminant removal for high-efficiency IGCC (fuel cell) and methanol plants.

Project Team: GTI, Siemens Power Generation, DOE-NETL

15

> ‘Warm gas’ (>260ºF) removal of multiple contaminants – sulfur, ammonia, HCl, mercury, other trace metals.

> Solvent with high temperature stability and high sulfur solubility

> Sulfur removed as pure liquid product

> Integrated loop to remove multiple other contaminants

UCSRP MultiUCSRP Multi--Contaminant ProcessContaminant Process

Project Team: GTI, University of California, ConocoPhillips, DOE-NETL, ICCI

Value: A new, inexpensive process for syngas contaminant removal and recovery for coal-based gasification processes.

16

bluegasbluegas®® Catalytic GasificationCatalytic Gasification

Value: Production of low-cost substitute natural gas (SNG) from coal.

>Sponsor: GreatPoint Energy

>Scope– Evaluate catalytic gasification for production of SNG from

two potential fuels– Laboratory tests followed by pilot-scale tests in Flex-Fuel

Test Facility

>Schedule– 18+ month program, started Jan 06

17

2004 - 2009

Component Development & Pilot Plant

Commercial Demonstrations (400 &

3000 TPD Gasifiers)2007 - 2010

Pilot Plant Gasifier & Test Facility

Commercial Gasification Plant

ComponentDevelopment

15% to 20% Lower End Product Cost from Improved Efficiency, Cost and Availability

15% to 20% Lower End Product Cost from Improved Efficiency, Cost and Availability

Pratt & Whitney Rocketdyne (PWR)Compact Gasification SystemValue: High-efficiency, low-cost advanced gasifier to

convert all coals to power and fuels.

18

Gasifier ComparisonGasifier ComparisonGE

GasifierShell

GasifierConocoPhillips Gasifier

Transport Gasifier

PWR Gasifier

90% Size Reduction Provides Significant Advantages

• Capital Cost• Availability*• Cold Gas Efficiency*• Fuel Flexibility• Product Flexibility

Base0.900.77FairGood

>Base0.850.83GoodFair

Base0.820.83FairFair

Base?0.75PoorPoor

<50%0.990.85GoodGood

* Based on public domain reports through DOE NETL and Gasification Technologies Council

19

FischerFischer--TropschTropsch Process Development UnitProcess Development UnitValue: Coal-to-liquids from Illinois basin coal.Sponsors: USDOE-Fossil Energy, Headwaters Energy Systems, GTI

Participants: Headwaters, GTI, Nexant, Argonne National Laboratory, DOE National Energy Technology Laboratory, Department of Defense/Air Force

Scope:• Design and build pilot-scale PDU to integrate with Flex-

Fuel Test Facility – use existing gasifier, gas cleaning and conditioning systems to pre-treat the syngas

• Produce F-T liquids and wax for downstream refining and evaluation (5-10 bpd) (DOE and DOD/AF to evaluate)

• Compare medium- and high-alpha catalysts• Compare slurry and fluidized bed operations• Test with syngas from various coals

• Train operating staff

20

Fischer Fischer TropschTropsch PDU Simplified Flow PDU Simplified Flow Diagram Diagram –– Syngas Feed from FFTFSyngas Feed from FFTF

21

Conceptual Plan forConceptual Plan forExpanded Gasification Test FacilityExpanded Gasification Test Facility

Oxygen supplySulfaTreat Morphysorb

Fischer-Tropsch PDU

Rocketdyne Gasifier

Labs & Offices

SOFC Slipstream Stack

22

Advantages of GTI LocationAdvantages of GTI Location

> Fast-track by integrating with existing facilities

> Existing gasifier for long-duration operation

> Flexibility in handling different fuels with air or oxygen as oxidant

> Existing gas cleaning and conditioning systems

> Facility already permitted

> Experienced scientists, engineers, and operators